Deck system components

ABSTRACT

A decking system is made up of a variety of decking boards and other components are disclosed. In some aspects, the decking boards are connectable to each other so that adjacent boards will provide a water barrier and a drainage channel. Some versions of the boards may have a hollow region to accept the provision of heating elements or other accessory structures. A connector piece is disclosed in various embodiments span the gap between the butt ends of the boards to provide a water barrier at the butt ends of the boards. A gutter and downspout system is disclosed, as well as structures for protecting the ends or sides of the deck structure.

CROSS REFERENCE TO RELATED APPLICATION

This application claims priority to U.S. Provisional Patent ApplicationSer. No. 61/602,346, entitled “Deck System and Components”, filed Feb.23, 2012 and U.S. patent application Ser. No. 13/465,512, entitled,“Deck System and Components”, filed May 7, 2012, the entire disclosuresof which are hereby incorporated by reference in its entirety.

BACKGROUND

1. Field of the Invention

Various aspects of the invention relate to structures such as floors,roofing and exterior decking, and more specifically, relate to deckboards, deck planks, porch boards, flooring, the connection of adjacentboards to each other, the connection of the end of boards to each other,and various accessories used with such structures.

Certain aspects of the invention relate to the management of rain water& melting snow to keep the underside of a deck system substantially dry,providing for storage of articles and the ability to have a first floorpatio/deck area underneath it without rain water affecting the enjoymentof the space or reaching the foundation of the house.

2. Description of Related Art

Deck systems are in wide use in both residential and commercialapplications. Some deck systems consist of simple wooden boards having arectangular cross-section each arranged longitudinally parallel to eachother onto a supporting structure. Similar systems are in use with thedeck boards being made of manmade material such as a composite orplastic based material.

These known systems sometimes have several disadvantages. For example,the parallel boards usually are spaced apart from each other laterallyto some degree, and even if the deck boards are abutting each otheralong their length, there is generally still some type of gap betweenthem. This gap between the long edges of the boards allows water to passthrough. Thus, when natural rain water or a cleaning water, spilledwater, melting snow or other liquid contacts the top surface of the deckboards, it will typically leak down through between the deck boards.This can be undesirable in situations where it is preferred that theregion under the deck surface be kept dry. Such situations includestructures having a deck surface on an upper floor and a residentialarea on a lower floor beneath the deck surface. Other situations whereit is preferred that the region under the deck surface be kept dryinclude decks having a dirt surface beneath the deck surface. By keepingthe dirt surface beneath the deck surface dry, the resident may preventthe dirt beneath the deck surface from becoming a haven for insects andweeds. In other commercial or industrial uses, it is desirable to keepliquids on the upper surface from inadvertently dripping to the lowerarea. In addition, where deck boards are also end-to-end, there istypically a space between the end surfaces of the deck boards. In someinstances a relatively wide space is left between the ends of the deckboards in order to allow for a thermal expansion and contraction ofboards placed end to end. This gap also can allow for undesirable fluidleakage or liquid leakage under the deck as described above.

Another disadvantage of some deck boards is that in some instances it isnecessary to screw the deck boards down to the supporting structure andin a conventional rectangular cross-section board, the screw heads areexposed on the top surface which may be undesirable for cosmetic orother reasons.

SUMMARY

In light of the present need for improved decking systems andaccessories, a brief summary of various embodiments is presented. Somesimplifications and omissions may be made in the following summary,which is intended to highlight and introduce some aspects of the variousembodiments, but not to limit the scope of the invention.

Various embodiments disclosed herein can relate to new and usefuldecking board constructions. For example, the decking board may featurean extruded cross-section having a generally tongue-and-groove matingfit between lateral and adjacent boards. In various embodiments, thedecking board may be a symmetrical, two sided product, with each sideoptionally having different pattern or color, thereby creating twoproducts in one. One side of the board may feature an upwardly directedU-shaped hook next to a downwardly directed groove or channel. The otherside of the decking board may have a complimentary, but opposite shaped,downwardly directed U-shaped hook adjacent to an upwardly directedgroove or channel. When the boards are interlocked side-to-side, eachhook will mate into each groove thereby providing secure connectionbetween the boards. Further, since the tongues and grooves areoverlapping, there is no vertical path for water on the top of the boardto pass in between the boards. In various embodiments, the upwardlydirected U-shaped tongue forms a primary water channel to collect anddirect water along the length of the structure to the end of thestructure.

In another aspect, a flashing element may be provided to act as a buttjoint to connect the butt ends of the boards. The flashing element has acomplimentary shape to the upper surface of the board, and can reside inlongitudinal grooves that are cut into the butt ends of the boards. Theflashing can also be a sharpened and or hardened element which isinstalled by tapping the first sharp end of the flashing element intothe relatively soft edge of the first board, and then bringing thesecond board into contact with the second end of flashing element andthen tapping the far end of the second board so that the second edge ofthe flashing element is pushed into the relatively soft first end of thesecond board. When installed, the flashing prevents water from passingdownward between the butt ends of the boards. In various embodiments,the flashing allows for expansion and contraction of the boards due tofluctuations between hot and cold environments. In one embodiment, ametal flashing that taps into place can be held in place by an integralstructure that then presses or affixes onto one or more edges of theboard or boards and holds it in place to make assembly easier.

Another embodiment of the butt joint involves installation of a polymerpart having a primarily “V-shaped” profile that flexes. The polymer parthaving a primarily “V-shaped” profile is installed between the butt endsof the planks. The flexing of the polymer part ensures a tight fit ismaintained during expansion and contraction of the planks.

In another aspect, the boards may feature one or more longitudinalhollow regions. The longitudinal hollow regions may accept a heatingelement such as a heatable wire or a heating fluid conduit or hose.Other heating elements such as radiant heating elements or hot aircontaining passages may reside in or be part of the interior of theboard. In some instances, a particular longitudinal hollow shape may beprovided, or the heating elements may be embedded in the structureduring manufacture.

In addition, at least one flexible member may be added inside the tongueand groove area on either part to align the planks when originallyinstalled tightly together and to also withstand the expansion andcontraction of the planks in the widthwise direction during hot and coldweather. Initially, at points of contact between adjacent tongues andgrooves of adjacent boards, a bumper protrusion may be provided on oneboard which will frictionally engage with a complimentary groove on theother board.

In another embodiment, a gutter may be added to the perimeter of thedeck surface to collect the water that is shed from the surface anddirect it downwards in a controlled fashion to connectors connecting toa leader which guides water away from the underside of the deck.

In another embodiment, the addition of a perimeter element may take theform of a bull nose type extrusion that provides some protection to theend boards when objects come in contact with the end of the deck. Thismay be particularly useful where the ends of the deck may come incontact with vehicles such as carts or, where the deck is being used asa dock and may come in contact with watercraft.

In another embodiment, the decking board comprises first and secondlongitudinal sides. The first longitudinal side has a male projectingmember with an upwardly directed rib and the second longitudinal sidehas a female slot defining a downwardly directed rib. The boards can beinterlocked adjacent each other with the upwardly directed rib snappedpast the downwardly directed rib to form a frictional engagementtherebetween. A central main body portion is disposed in longitudinalsides.

In another embodiment, the decking board comprises a first longitudinalside having an extension member including a first surface and anopposing second surface, the first surface including an upwardlyprojected abutment defining a first lip. The second surface has a recessformed therein. The second longitudinal side includes a first portiondefining a tongue and a second portion including a second lip. Thetongue includes a first flexible member extending generally upward fromthe first portion. The second lip includes a second flexible memberextending generally downward from the second portion.

a main central body disposed intermediate to the first longitudinal sideand second side;

wherein the first portion and second portion of the second longitudinalside define a cavity therebetween to receive an extension member of anassociated decking board therein.

In another aspect, a dock board may be provided in the form of arelatively simple dock board extrusion.

BRIEF DESCRIPTION OF THE DRAWINGS

In order to better understand various exemplary embodiments, referenceis made to the accompanying drawings, wherein:

FIG. 1A shows various elements of a decking system, including deckingboards and a flashing element.

FIG. 1B is a cross-section of the embodiment of FIG. 1A.

FIG. 1C is a detailed view of a part of the cross-section of FIG. 1B.

FIG. 1D shows a cross-section of one embodiment of a decking board.

FIG. 1E shows a cross-section of another embodiment of a decking board.

FIG. 1F shows a cross-section of yet another embodiment of a deckingboard.

FIG. 2A shows a number of decking boards according to the embodiment ofFIG. 1F in an installed condition.

FIG. 2B shows additional details of the system of FIG. 2A.

FIG. 2C shows a number of decking boards according to the embodiment ofFIG. 1E in an installed condition.

FIG. 3A illustrates a drain and gutter system.

FIG. 3B is an exploded view of the system of FIG. 3A.

FIG. 3C is a further exploded view of the system of FIG. 3A.

FIG. 3D depicts components of the drain and gutter system.

FIG. 3E shows a drain and gutter system corner connector

FIG. 4 shows a cross-section of a component of the drain and guttersystem having a bull nose profile.

FIG. 5 shows a simplified decking board in the form of a dock plank.

FIG. 6 shows a bull nose component for mounting to the end a deck ordock system.

FIGS. 7A and 7B show polymer parts which aid in connecting planks ofFIG. 1 in an end-to-end relationship.

FIG. 8A is a cross-sectional view of another embodiment of a deckingboard.

FIG. 8B shows two decking boards according to FIG. 8A joined together.

FIG. 9A is a cross-sectional view of another embodiment of a deckingboard.

FIG. 9B shows two decking boards according to FIG. 9A joined together.

FIG. 10A is a cross-sectional view of another embodiment of a deckingboard.

FIG. 10B shows two decking boards according to FIG. 10A joined together.

FIG. 11A is a cross-sectional view of another embodiment of a deckingboard.

FIG. 11B is a side view of the board of FIG. 11A.

FIG. 11C is a bottom view of the board of FIG. 11A.

FIG. 11D is a top view of the board of FIG. 11A.

FIG. 11E is a cross-sectional view of two boards according to FIG. 11Amounted together.

FIG. 12A is a cross-sectional view of another embodiment of a dockboard.

FIG. 12B is a side view of the dock board of FIG. 12A.

FIG. 12C is a bottom view of the dock board of FIG. 12A.

FIG. 12D is a top view of the dock board of FIG. 12A.

FIG. 13A is a side view of a decking board system, illustrating twodecking boards in locking engagement.

FIG. 13B is a cross-sectional view of another embodiment of a deckingboard.

FIG. 13C is a sectional view of the decking board of FIG. 13B, furtherillustrating the decking board connection and fastening component.

FIG. 13D is a side view of a decking board system of FIG. 13Aillustrating the attachment of plural decking boards.

DETAILED DESCRIPTION

Referring now to the drawings, in which like numerals refer to likecomponents or steps, there are disclosed broad aspects of variousexemplary embodiments.

The board is used herein to refer to any type of longitudinal surface orsubstrate board. Some embodiments are referred to as decking boards, butany embodiments could be used in porches, floors, roofing or other usesas will be understood by one skilled in the art of constructioncomponents.

Various embodiments disclosed herein can relate to new and usefuldecking board constructions. For example, the decking board may featurean extruded cross-section having a generally tongue-and-groove matingfit between lateral and adjacent boards. One side of the board mayfeature an upwardly directed U-shaped hook next to a downwardly directedchannel. The other end of the decking board may have a complimentary,but opposite shaped, downwardly directed U-shaped hook adjacent to anupwardly directed groove. When the boards are interlocked side-to-side,each hook will mate into each groove thereby providing secure connectionbetween the boards. Further, since the tongues and grooves areoverlapping, there is no vertical path for water on the top of the boardto pass in between the boards. In addition, the downwardly directedU-shaped tongue forms a water channel to collect and direct water alongthe length of the structure to the end of the structure.

FIG. 1A depicts a deck system 10 including a plurality of decking boards12. Each board 12 has a downwardly directed tongue 14 which has anupwardly facing groove 16. Located inward of the downward facing tongue14 is a downward facing groove 18. A reversed structure is provided onthe other side of the board 12 including an upward facing tongue 20having a downward facing channel 22. Located inward of the upward facingtongue 20 is an upward facing groove 24. FIG. 1A also shows the boardsinterconnected with each other with the downward facing tongue 14residing in the upward facing groove 24 of an adjacent board. Thefarthest edge 26 of the downward facing tongue 14 slides against aresilient tab 28. Similarly, the outer surface 30 of the board will abutagainst a tab 32 in an adjacent board. In the assembled system,therefore, a water collecting channel 40 is provided which appears fromthe upper surface of the deck as a simple downward rectangular channel.In various embodiments, the boards are symmetrical so the customer canturn the decking boards upside down while still allowing interconnectionbetween the boards. In some embodiments, the symmetrical boards haveidentical patterns and colors on each side. This contributes to ease ofassembly, as each board may be used with either side uppermost. In someembodiments, the symmetrical boards have different patterns or colors oneach side. The presence of different patterns or colors on each side ofthe decking boards allows the customer to choose between two differentor complementary surface styles while buying only one board itemversion.

In another aspect, a flashing element may be provided to connect thebutt ends of the boards. The flashing element has a complimentary shapeto the upper surface of the board, and can reside in longitudinalgrooves that are cut into the butt ends of the boards. When installed,the flashing element prevents water from passing downward between thebutt ends of the boards. This is true even if a relatively wide end toend gap is selected to allow for thermal expansion and contraction.

Into the end of each board is cut a slot 42 which extends apredetermined distance into the board, but not all the way through itslength. The slot 42 is sized to receive the insertion of a flashingelement 50. The flashing element, therefore, resides in the slots 42 inthe butt ends of boards 12 placed end to end, and prohibits any waterflow between the ends of the boards. To the extent the flashing element50 is visible between butt end gap between the boards, any liquid thatcontacts the flashing will be directed into a channel portion 52 of theboard and will, once a certain volume of liquid is reached, be carriedaway by channel 40. The flashing element 50 can be made from folded orextruded metal and may have its edges sharpened for tapping into placeinto slots 42 in the butt ends of the boards.

In various embodiments, the flashing can be a sharpened and/or hardenedelement which is installed by tapping the first sharp end of theflashing element into the relatively soft end of a first board, and thenbringing a second board into contact with the second end of flashingelement and then tapping the far end of the second board so that thesecond edge of the flashing element is pushed into the relatively softfirst end of the second board. In such embodiments, the presence ofslots 42 in the butt ends of boards 12 is optional.

A feature of the boards 12 shown in FIG. 1A is that they can be slidtogether along their length. That is, rather than snapping the boards intogether to mate from the top, which is possible, another assemblyoption is to slide the boards together end to end, one next to another.Accordingly, boards can be assembled into an overlapping deck withoutthe use of any hardware to hold the boards to each other.

A device for facilitating formation of watertight butt joints is shownin FIG. 7A, It is a polymer part 700 that has a primarily “V-shaped”profile 701 that flexes during installation between the butt ends of theplanks. The butt ends of the planks contact the outer surface of the“V-shaped” profile 701. Flexing of the profile 701 ensures a tight fitis maintained during expansion and contraction of the planks. Thepolymer part 700 may also have a hidden tape or other sealant materialto keep the butt joint in place and provide further water sealantability. The polymer part 700 may have one or more snap provisions tohold it down in place between the ends of the planks. This “V-shaped”profile 701 directs the water that would normally have fallen betweenthe ends of the planks into channel 702, which fits into rain grooves 40in the planks and bridges rain grooves in two planks in an end-to-endrelationship. Channel 702 guides water into the rain groove 40 in FIG.1A.

Another embodiment of the device for facilitating formation ofwatertight butt joints is shown in FIG. 7B, and is a polymer part 210that has a primarily “T-shaped” profile 711 installed between the buttends of the planks, with the vertical member of the “T-shaped” profile711 fitting between the butt ends of the boards. The polymer part 710may have a sealant or tape used to keep it in place and may have one ormore snap provisions to keep it in place between the ends of the deckplanks. The horizontal member of the “T-shaped” profile 711 covers thetop surface of the planks and has a “U-shaped” extension forming channel712 that fits on top of and spanning the space between the ends of therain grooves 40 of the planks whose ends are being joined. Thisembodiment may or may not have some sealant, tape or snap fit to helphold it into place.

In an alternate embodiment, a device for facilitating formation ofwatertight butt joints is a polymer part 710 that has a primarily“I-shaped” profile installed between the butt ends of the planks, withthe vertical member of the “I-shaped” profile fitting between the buttends of the boards. The “I-shaped” profile has an upper horizontalmember which covers the top surface of the planks and has a “U-shaped”extension forming a channel that fits on top of and spans the spacebetween the ends of the rain grooves 40 of the planks whose ends arebeing joined. The “I-shaped” profile has a lower horizontal member. Thebutt ends of the boards fit between the upper and lower horizontalmembers.

Device 700 and 710 for facilitating formation of watertight butt jointsmay have a snap fit feature for securing them between boards.

Returning to FIG. 1A, the boards may also be assembled by installing afirst board having an upwardly facing groove 24, and then connecting asecond board having a downwardly facing tongue 14 to the first board.This is done by placing the downwardly facing tongue 14 of the secondboard over the already installed first board. Then the second board'sdownwardly facing tongue 14 is aligned over the first board's upwardlyfacing groove 24 and the second board is dropped down onto and over thetop of the edge of the first board so tongue 14 goes into groove 24. Thesecond board then slides into the groove 24 of the first board, tightlyagainst the first board, so that the edge 26 of the downward facingtongue 14 slides against a resilient tab 28 in groove 24. The edge 26 ofthe downward facing tongue 14 makes tight contact with tab 28. Thiscreates a perfect alignment between the boards as the installer putsscrews down onto the surface of grooves 24, securing the boards inplace. This also contributes to the water tightness of channel 40, whichalso has upwardly facing and downwardly facing interconnecting elements.The resilient tab 28 allows for thermal based expansion of the boardsafter assembly. It may be desirable to mount the boards to an underlyingstructure (this will be described further with reference to FIG. 2Ausing the board of FIG. 1F). The board of FIG. 1A provides aconveniently accessible mounting location for such screws through thesurface of the groove 24, which may or may not be pre-drilled with holes63 for ease of installation.

In another aspect, the boards may feature one or more longitudinalhollow regions 62. The longitudinal hollow regions may accept a heatingelement such as a heatable wire or a heating or cooling fluid conduit orhose. Other thermal elements such as radiant heating elements or hot aircontaining passages may reside in or be part of the interior of theboard. In some instances, a particular longitudinal hollow shape may beprovided, or the heating elements may be embedded in the structureduring manufacture.

The board 12 also includes a main body region 60. This main body region60 may be solid or may be provided with one or more hollow regions 62.The hollow region 62 may provide a number of benefits including, forexample, reducing the weight of the board compared to a solid board.Further, the hollow region 62 may allow for the insertion of heatingdevices. The board depicted in FIG. 1A also features stiffening ribs 64.These ribs 64 can provide stiffening, and can also maintain heatercables separate from each other if they are installed in back and forthrows.

It is also noted that the openings 62 may have a wide variety of shapesas are shown in the other figures, and other cross-sectional shapes. Inaddition to or instead of containing heating elements, other items suchas wires for power outlets, speakers, dog fences, or other wire basedproducts may be passed through the hollow portions 62.

In another aspect, a flexible assembly tab or member such as tab 28, 32and 128 may be provided on the boards near the tongue and groove regionto provide a firm frictional contact between the adjacent tongues andgrooves and to align the boards during assembly. Initially, at points ofcontact between adjacent tongues and grooves of adjacent boards, abumper protrusion may be provided on one board which will frictionallyengage with a complimentary groove on the other board. It is also notedthat tabs 28, 32 and 128 provide a stop feature during the assemblyprocess, but further allow for lateral expansion and contraction of theboards during temperature extremes. The tabs 28, 32 nd 128 may bereferred to as flexible members. The resilient or flexible members mayprovide for alignment and frictional engagement. They may thus be in aslightly bent configuration in the assembled state. However the tabs mayalso be sacrificial in that they are designed to be breakable orfrangible, that is, they may break off upon application of sufficentforce during installation of adjacent boards.

FIG. 1D shows a decking board having a different cross-section from FIG.1A. This board 112 may be thought of as having a tongue 114 whichprojects into a groove 124. An upward facing channel 116 is providedthat will function similarly to the channel 16 described above. Aresilient tab 128 is also provided. Instead of an upwardly directedtongue, this embodiment features a laterally extending tongue 120. Thetongue 120 can provide for a screw location similar to that in thechannel 24 and may or may not be pre-drilled with holes for easyassembly. The tongue 120 can also nest in a rectangular notch 118provided on the other side of an adjacent board. An additional reliefarea 119 is provided on the lower surface of the tongue 114 whichpermits clearance for a screw head. The embodiment of FIG. 1D features asingle central hollow area 162. FIG. 1D also schematically depictsheating elements 170 in hollow portion 162.

FIG. 1E shows a deck board similar to the board of FIG. 1D, but withoutthe central hollow area 162. FIG. 1E shows a decking board having atongue 114 which projects into a groove 124. A resilient tab 128 is alsoprovided. This embodiment features a laterally extending tongue 120. Thetongue 120 can nest in a rectangular notch 118 provided on the otherside of an adjacent board. The embodiment of FIG. 1D optionally includesa pivot bump 117, and a pocket 126. Pocket 126 is adapted to receive amounting screw. However the pocket 126 can also serve as a track foraccepting a longitudinal heating wire 130 as shown.

FIG. 1F shows a deck board having a similar outer profile to that ofFIGS. 1D and 1C, but having a central hollow opening 162 that includesstiffening ribs 164. FIG. 1D also illustrates that the lower surface ofthe hollow region 162 has a parabolic concave upward shape to reflectheat upwards. A fastener 66 is shown being screwed into hole 63 formounting.

FIGS. 2A and 2B show additional details utilizing the board of FIG. 1F.In this embodiment, the board of FIG. 1F has been further provided witha bump/rib 115 and a corresponding bump/rib 125. Instead of both items115 and 125 being projecting bumps, one or the other could be a smallgroove notch, dimple or detent. It will be appreciated that as shown inthe lower portion of FIG. 2A, the bumps/ribs 115 and 125 can engage eachother to enhance the frictional connection of adjacent boards. Anotherbump or protrusion 117 may be placed at the edge of the bottom surfacenext to 118. This bumper creates a pivot point for the plank so thatwhen fastening the board at area 120, the wall tongue 114 is pushedupwards to create a tight fit between the seal elements 115 & 125.Further, FIG. 2A depicts installation screws being placed through thelaterally extending tongues 120.

In this embodiment, a top surface 111 of each board 112 has a slightlycrowned surface to direct water towards the water channels 140 betweenthe boards. FIG. 2A also shows further details of the interactionbetween the bump/ribs 115 and 125, and screws 127.

FIG. 2C shows an embodiment in which the board has been further providedwith a bump/rib 115 and a corresponding bump/rib 125. In the embodimentof FIG. 2C, the boards are provided with pockets 126, and are assembledso that pockets 126 of the boards are aligned under tongues 114 of anadjacent board. The water channel 140 defined by tongue 114 of theadjacent board is thus positioned above pocket 126. Pocket 126 isprovided with heating wire 130. Heating wire 130 provided in one boardthus serves to heat channel 140 defined by tongue 114 of the adjacentboard. Channel 140 is a groove for carrying rainwater. Heating wire 130serves to prevent rainwater or melting snow in channel 140 fromfreezing.

At the end of a board, the wire 130 may be bent and wrapped around theend of the plank to an adjacent plank. The wire then fits into pocket126 on the adjacent plank, and travels longitudinally along the adjacentplank. Notches 131 may be provided at the ends of the boards to guidethe wire from one plank to another. Heating wire 130 can be acylindrical wire or a flat or rectangular wire having two opposed majorsurfaces and two opposed edge surfaces. If a flat wire is used, then thewire should be arranged so that the opposed major surfaces are vertical,i.e., perpendicular to the upper surface of the boards. If the opposedsurfaces are horizontal, it is more difficult to bend the wire at theend of the plank.

Pocket 126 and heating wire 130 may also be installed in the outer edgeof tongue 114 or in groove 124. Each of these locations places theheating wire in proximity to channel 140, allowing the heating wire toheat water in the channel.

In another aspect, a drain system may be provided at the longitudinalend of a deck that is made up of adjacent boards. The drain system mayinclude a main T-downspout piece which collects and directs water to aleader, and individual adjacent gutter pieces that connect to theT-downspout. These can be mounted at the ends of the boards on thesupporting structure.

FIGS. 3A, 3B, 3C and 3D depict various components of a gutter system.The gutter system can be used with any deck that can direct and shedsurface water, including the decking systems described herein. Thegutter system generally includes a main T-downspout 210 and adjacentgutter pieces 212. The main T-downspout 210 can connect with a leaderdownspout 214. The gutter portions 212 may feature an outwardly curvedprojecting shape 212 a which may provide some bumper protection for theend of the overall decking structure and provide a pleasing appearanceby hiding the cut edges of the planks and hiding the heater wire thatmay be installed and running through and between each plank. Such arounded outward portion may also be provided on the main T-downspout(although not shown) or this feature may be provided by a separate cover216 that can be mounted along with T-downspout to cover it as shown.FIG. 3 illustrates these components and further illustrates a cornerpiece 318.

In another embodiment, the gutter may form a bull nose type extrusionthat provides some protection to the end boards when objects come incontact with the end of the deck. This may be particularly useful wherethe ends of the deck may come in contact with vehicles such as carts or,where the deck is being used as a dock and may come in contact withwatercraft. FIG. 4 shows a cross-section of a bull nose structure 400that can provide a relatively simple gutter and/or bumper item that maybe mounted on the edge and the end of a deck system. Alternatively, thelower portion of this type gutter extrusion can be made of variouslengths so as to be useful for cutting off and using as a trim board inother areas of the deck as needed.

In another aspect, a dock board may be in the form of a relativelysimple dock board extrusion. FIG. 5 shows a deck board in the form of arelatively simple dock plank. This plank 500 features a relatively flattop surface, tilted sides 512, and upwardly directed recesses 514. Therecesses 514 may assist with saving weight by still providinglongitudinal bending strength.

In another aspect, a bull nose structure may be provided that does notprovide water gutter features, but rather provides a projecting cushionstructure at the end of the deck similar to the bull nose describedabove. FIG. 6 depicts a bull nose structure that can be used similar tothe bull nose of FIG. 4. However, this structure has a differentcross-sectional shape with structure 600 has a different cross-sectionalshape including a mounting tab 612, and a rounded compressibleprojection 614 that has a central lap 616.

Any or all of the various deck boards, dock boards, downspouts, guttersor bumpers and other components can be manufactured from any suitablematerial. In many embodiments, the various items can be manufactured byextrusion methods. Any suitable extrudable material may be used. In someembodiments the boards can be manufactured using a compression moldingprocess. In some examples, the items may be manufactured, by extrudingor otherwise, from hydrophobic polymers, i.e., PVC or polyolefins, andhydrophobic coconut coir fibers which have been treated to removecoconut coir therefrom. In various embodiments, the composite items maybe manufactured without any step chemically modified coconut coirfibers. However, the disclosure herein is not limited to the use ofcoconut based materials. For example, as an alternative to coir fibers,extruded materials may include ramie or bamboo fibers to reinforcepolymeric products. In other embodiments, the materials may simply beextruded or molded from polymeric and/or wood based composite extrudableor moldable materials. Simple plastics may also be used. Further, it maybe preferable to manufacture the flashing of a metal such as stainlesssteel or extruded metals.

The decking boards may be made by extrusion of a thermoplastic material,i.e., polyester, polyvinyl chloride, or polyolefin, preferablypolyethylene or polypropylene. The thermoplastic material may contain afiller, including organic fillers such as wood powders, wood fibers, andcoir fibers; inorganic fillers, such as glass fibers, carbon fibers,mineral fibers, silica, alumina, titania, carbon black, nitridecompounds, and carbide compounds. The decking boards may be uncoated, orcoated with a decorative coating of paint. The decking boards may becoated with a protective coating. The protective coating may be appliedby coating a mixture of monomers and/or oligomers on the completedboard, and then curing the coating to form a protective coating.

Coated decking boards may also be made by coextrusion of:

a core layer comprising a thermoplastic material, i.e., polyethylene orpolypropylene, containing optional fillers, including organic fillerssuch as wood powders, wood fibers, and coir fibers; inorganic fillers,such as glass fibers, carbon fibers, mineral fibers, silica, alumina,titania, carbon black, nitride compounds, and carbide compounds; and

a coating layer (such as for example PolyEthylene with additives) of aprotective thermoplastic polymer. Suitable protective polymers includepolyvinyl chloride; acrylic resins, i.e., poly(ethylene-co-methacrylicacid) (Surlyn®); polyester; polycarbonate; and polystyrene.

In various embodiments, the coating layer contains UV stabilizers whichreduce the likelihood of the core layer undergoing degradation fromexposure to ultraviolet light. Such UV stabilizers include organic lightstabilizers, such as benzophenone light stabilizers, hindered aminelight stabilizers, and benzotriazoles; and inorganic light stabilizers.such as barium metaborate and its hydrates.

In various embodiments, the coating layer contains antifungal agentswhich increase resistance of the board to mold and other organisms. Theantifungal agents may be incorporated in the coating layer alone, or inboth the core and coating layers. Useful antifungal agents for coatingsinclude copper (II) 8-quinolinolate; zinc oxide;zinc-dimethyldithiocarbamate; 2-mercaptobenzothiazole; zinc salt; bariummetaborate; tributyl tin benzoate; bis tributyl tin salicylate; tributyltin oxide; parabens: ethyl parahydroxybenzoate; propylparahydroxybenzoate; methyl parahydroxybenzoate and butylparahydroxybenzoate; methylenebis(thiocyanate);1,2-benzisothiazoline-3-one; 2-mercaptobenzo-thiazole;5-chloro-2-methyl-3(2H)-isothiazolone; 2-methyl-3(2H)-isothiazolone;zinc 2-pyridinethiol-N-oxide;tetra-hydro-3,5-di-methyl-2H-1,3,5-thiadiazine-2-thione;N-trichloromethyl-thio-4-cyclohexene-1,2-dicarboximide;2-n-octyl-4-isothiazoline-3-one; 2,4,5,6-tetrachloro-isophthalonitrile;3-iodo-2-propynyl butylcarbamate; diiodomethyl-p-tolylsulfone;N-(trichloromethyl-thio)phthalimide; potassiumN-hydroxy-methyl-N-methyl-dithiocarbamate; sodium2-pyridinethiol-1-oxide; 2-(thiocyanomethylthio)benzothiazole; and2-4(-thiazolyl)benzimidazole.

The coating layer may help provide scratch resistance to the deckingboard surface, either by using a coating with a polymer which is harderthan the core layer or through the use of certain additives. Additiveswhich help increase scratch resistance in coatings include lubricantsand very hard mineral fillers, including carbide and nitride ceramics.

The coating layer may also include inorganic pigments, organic pigments,or dyes as colorants. The coating layer may be embossed with adecorative pattern, i,e., wood grain or imitation stone.

In situations where a coating layer or “capcoat” is applied bycoextrusion. the coating layer has a thickness of from about 0.01 to0.25 inch, preferably from about 0.02 to 0.15 inch, more preferably fromabout 0.04 to 0.08 inch. The capcoat may cover the entire longitudinalsurface of the board; the top and sides of the board, with the bottomsurface being uncoated; or the top of the board, with the bottom surfaceand sides being uncoated.

As discussed above, at least one flexible member may be added inside thetongue and groove area on the decking planks to align the planks to helpwithstand expansion and contraction of the planks. Also, a bumperprotrusion may be provided on a board which will frictionally engagewith a complimentary groove on another board. In various embodimentsmade by coextrusion of a core material and a capcoat, these flexiblemembers and bumpers may be formed from the same material as the corematerial, and optionally coated with the capcoat material. In variousembodiments made by coextrusion, these flexible members and bumpers maybe formed from the capcoat material alone. In certain embodiments,flexible members and bumpers formed from the capcoat material haveincreased toughness, resistance to breakage, and flexibility, whencompared to embodiments in which flexible members and bumpers are madefrom the core material, i.e., a wood fiber- or coir fiber-filledpolyolefin.

A further design for a flexible member produced from a capcoat polymerlayer can be envisioned to be attached to the outside edge of the tongueportion, i.e., on the outside edge 26 of the tongue 14, or on the outersurface of rain-groove element 40, as seen in FIG. 1A. The flexiblemember produced from the capcoat polymer can thereby set the assemblygap between planks during installation. Additionally, a flexible memberproduced from the capcoat polymer and positioned on edge 26 may contactan inner surface of groove 24, when boards are fitted together as inFIG. 1A. This provides a flexible water seal between boards as boardsexpand with heat and then contract again.

A further design for a flexible member (not shown in FIG. 1C) producedfrom a capcoat polymer layer can be envisioned to be attached to theouter edge of the tongue portion 114 or 116, as seen in FIG. 1C, andadapted to contact the interior of groove 124, as seen in FIG. 1C.Contact between flexible members produced from a capcoat polymer layerand groove 124 of FIG. 1C produces a flexible water seal.

Also, a bumper protrusion may be provided on a board which willfrictionally engage with a flexible member made of capcoat material onanother board. The cap coat material is a tough resilient polymer, andmay be used to produce watertight elements.

FIG. 8A is a cross-sectional view of a board 800 having a top cap coat801 and a lower cap coat 802. A male side of the board 814 includes anupwardly projecting bump 816 and a lower pivot bump 817. A female side820 of the board includes a projecting bump 822 that can snap over andinterlock with the projecting bump 816, a flexible tap 832, which canhelp hold the boards together in alignment, and accommodate forexpansion of the boards, and a water drain channel 824. Further, thefemale end has an open area to the inside of the flexible tab 832 whichcan be sized and dimensioned to receive a heating wire or cable. FIG. 8Ashows the heating element 870 as having a generally vertical rectangularcross-section.

FIG. 8B shows two of the boards 800 interlocked adjacent to each other.

FIG. 9A is a cross-sectional view of a board 900 having a top cap coat901 and a lower cap coat 902. This board is narrower than that of FIG.81 and thus may be more suitable for use as a porch board in someinstances. A male side of the board 914 includes an upwardly projectingbump 916 and a lower pivot bump 917. A female side 920 of the boardincludes a projecting bump 922 that can snap over and interlock with theprojecting bump 916, a flexible tap 932, which can help hold the boardstogether in alignment, and accommodate for expansion of the boards, anda water drain channel 924. Further, the female end has an open area tothe inside of the flexible tab 932 which can be sized and dimensioned toreceive a heating wire or cable. FIG. 9A shows the heating element 970as having a generally vertical rectangular cross-section.

FIG. 9B shows two of the boards 900 interlocked adjacent to each other.

FIG. 10A is a cross-sectional view of a board 1000 having a top cap coat1001 and a lower cap coat 1002. A male side of the board 1014 includesan upwardly projecting bump 1016 and a lower pivot bump 1017. A femaleside 1020 of the board includes a projecting bump 1022 that can snapover and interlock with the projecting bump 1016, a flexible tap 1032,which can help hold the boards together in alignment, and accommodatefor expansion of the boards, and a water drain channel 1024. Further,the female end has an open area to the inside of the flexible tab 1032which can be sized and dimensioned to receive a heating wire or cable.FIG. 10A shows the heating element 1070 as having a generally verticalrectangular cross-section.

FIG. 10B shows two of the boards 1000 interlocked adjacent to eachother. In this embodiment, the aperture on the female end is shaped morevertically, so that the heating element can be oriented more vertically.

FIG. 11A is a cross-sectional view of a board 1100 having a top cap coat1101 and a lower cap coat 1102. A male side of the board 1114 includesan upwardly projecting bump 1116 and a lower pivot bump 1117. A femaleside 1120 of the board includes a projecting bump 1122 that can snapover and interlock with the projecting bump 1116, a flexible tab 1132,which can help hold the boards together in alignment, and accommodatefor expansion of the boards, and a water drain channel 1124. Further,the female end has an open area to the inside of the flexible tab 1132which can be sized and dimensioned to receive a heating wire or cable.FIG. 11A shows the heating element 1170 as having a generally verticalrectangular cross-section.

FIG. 11B shows two of the boards 1100 interlocked adjacent to eachother.

The female sided of the boards of FIGS. 8A through 11D form a partiallyenclosed conduit for holding the heating element 870, 970, 1070, 1170,etc. When the boards are installed adjacent each other the male sides insome embodiments will substantially enclose the female-side conduit sothe heating element is not exposed to water.

FIGS. 12A-12D show the cross-sectional and other views of a dock board1200.

Referring now to FIGS. 13A-13D, there is shown a decking board system1312 including plural decking boards, in interlocking position. As shownin FIGS. 13A and 13B, the decking board 1300 generally includes a topcap coat 1301 and lower cap coat 1302, as similarly disclosed inprevious embodiments. As further shown, the decking board 1300 includesa male side or first longitudinal side 1306 of the decking board, afemale side or second longitudinal side 1308, and a main body 1304intermediate to the male side 1306 and second side 1308.

In the decking system 1312, the decking boards 1300 are configured forinterlocking engagement with each other. As shown, the male side 1306 ofthe decking board 1300 is configured for cooperative interlockingengagement with the female side 1308 of an associated decking board1300. To facilitate this engagement, the male side 1306 generallyincludes an extension member 1314, which extends generally laterallyoutward from the male side 1306. The extension member 1314 is configuredfor insertion into the female side 1308 of an associated decking board1300 in the system 1312.

The extension member 1314 generally includes a first surface 1326 and anopposing second surface 1336 defining a notch 1337. As shown, theextension member 1314 further includes a generally upwardly projectingfirst lip 1316 positioned, proximate to the first surface 1326. Theextension member 1314 further defines an opening 1338 configured toreceive a tongue 1320 from an associated decking board 1300 therein. Theconfiguration of the male side 1306 in combination with the extensionmember 1314 provides a u-shaped configuration 1340.

The female side 1308 of the decking board 1300 generally includes afirst portion or tongue 1320 and a second portion 1321 including asecond lip 1322 or bump. The first portion 1320 and second portion 1321have an opening formed therebetween defining a cavity 1362 configured toreceive an extension member 1314 of a male side therein.

As shown in FIG. 13B, the second lip 1322 extends in a generallydownward direction from the second portion 1321 and is configured forsnapping and/or interlocking engagement with a first lip 1316 providedby an associated decking board 1300. The second portion 1321 furtherincludes a second flexible member 1324, positioned generally adjacent tothe second lip 1322, along the inner surface 1330 of the second portion1321.

The second flexible member 1324 extends in a generally downwarddirection from the inner surface 1330 such that when the decking board1300 is in locking engagement with an associated decking board, thesecond flexible member 1324 engages the surface 1326 of the extensionmember 1314. The second flexible member 1324 has at least one prongextending generally downward. As shown in FIG. 13C, the second flexiblemember 1324 may have a two-prong configuration for engagement with theextension member 1314. The first prong 1333 of the second flexiblemember 1324 may form a second seal, and the second prong 1331 of thesecond flexible member 1324 may form a third seal. Notably it iscontemplated that the second flexible member 1324 can include more thantwo prongs 1331, 1333, without departing from the scope of the presentinvention. It is further contemplated that multiple second flexiblemembers 1324 can be provided on the inner surface 1330 to provideadditional seals with the extension member 1314, without departing fromthe scope of the present invention.

The tongue 1320 extends generally laterally outward from the female side1308. As shown, the tongue 1320 has a generally sloped inner surface1332. The female side 1308 of the decking board further includes atleast one first flexible member 1328, which extends from the surface1332 in a generally upward direction. As such, the first flexible member1328 is configured for engagement with an extension member 1314 of anassociated decking board 1300 Notably it is contemplated that the firstflexible member 1328 can include multiple prongs or members to providemultiple points of engagement with the extension member 1314. Further itis noted that one or more first flexible members 1328 can be provided onthe tongue 1320 to provide multiple seals with the extension member 1314to further block moisture.

FIGS. 13A and 13D shows a decking board system 1312 including a firstdecking board 1300 a and a second decking 1300 b, configured to beinterlocked adjacent to each other. As shown, the extension member 1314a of decking board 1300 a is inserted into cavity 1362 b of the deckingboard 1300 b. The second flexible member 1324 b and first flexiblemember 1328 b cooperatively engage the extension member 1314 a. As such,the second flexible member 1324 b engages the surface 1326 a of theextension member 1314 a forming a seal, and the first flexible member1328 b engages the notch or recess 1337 a. The first lip 1316 a of theextension member 1314 a engages the inner surface 1330 b of the deckingboard 1300 b. The second lip 1322 b of the decking board 1300 b engagesthe inner surface 1326 a of the decking board 1300 a. Additionally, thetongue 1320 b is inserted below the surface 1338 a.

As shown in FIG. 13C, the decking board 1300 provides an opening 1342for receiving a fastening member or component, such as a bolt or screw.As such, the decking board 1300 may be secured to an adjacent surface.Additionally, FIG. 13C illustrates that when the decking boards are inengagement, channel 1340 is formed between the decking boards 1300 a,1300 b to facilitate fluid removal from the decking board surfaces.

Although the various embodiments have been described in detail, itshould be understand that the invention that the invention is capable ofother embodiments and its details are capable of modifications invarious obvious respects. As is readily apparent to those skilled in theart, variations and modifications can be affected while remaining withinthe spirit and scope of the invention. Accordingly, the foregoingdisclosure, description, and figures are for illustrative purposes onlyand do not in any way limit the invention, which is defined only by theclaims.

What is claimed is:
 1. A decking board, comprising: a first longitudinalside having an extension member including a first surface and anopposing second surface, the first surface including a first lip, thesecond surface having a recess formed therein; a second longitudinalside including a first portion defining a tongue and a second portionincluding a second lip, the second longitudinal side further including afirst flexible seal member; and, a main central body disposedintermediate to the first longitudinal side and second side; wherein thefirst portion and second portion of the second longitudinal side definea cavity therebetween to receive an extension member of an associateddecking board therein.
 2. The decking board of claim 1, the tongueincluding a first flexible seal member extending generally upward fromthe first portion, the second portion including a second flexible sealmember extending generally downward from the second portion.
 3. Thedecking board of claim 2, wherein the first flexible seal member isconfigured to operatively engage the second surface of an associatedextension member when the associated extension member is inserted in thecavity.
 4. The decking board of claim 2, wherein the second flexibleseal member is configured to operatively engage a first surface of anassociated extension member when an extension member is inserted in thecavity,
 5. The decking board of claim 4, wherein the second flexibleseal member has a flexible prong extending generally downward from thesecond portion of the second longitudinal side.
 6. The decking board ofclaim 5, wherein the second flexible member includes a first prongextending generally downward from the second portion of the secondlongitudinal side and a second prong defining a third flexible sealmember extending generally downward from the second portion of thesecond longitudinal side.
 7. The decking board of claim 1, wherein thefirst portion of the second longitudinal side includes an opening formedtherein to receive a fastening member to secure the decking board to anassociated surface.
 8. The decking board of claim 1, wherein the firstflexible member is configured to engage a recess of an associateddecking board.
 9. The decking board of claim 1, wherein the firstportion of the second longitudinal side and extension member of thefirst longitudinal side are configured such that when a first deckingboard and a second decking board are interlocked, a channel is formedbetween the first portion of the second decking board and the extensionmember of the first decking board.
 10. The decking board of claim 1,wherein the first lip is an upwardly projected abutment.
 11. The deckingboard of claim 1, wherein the second lip is a downwardly projectedabutment.
 12. A decking board, comprising: a first body portion, acentral body portion; and, a second body portion including a firstportion including a first flexible member, and a second portionincluding a second flexible member, wherein the first flexible memberand second flexible member are configured to cooperatively engage anextending member of an associated decking board.
 13. The decking boardof claim 12, wherein the first portion and second portion provide acavity therebetween to receive the extending member.
 14. The deckingboard of claim 12, wherein the first flexible member is configured toengage a lower portion of an extending member of an associated deckingboard.
 15. The decking member of claim 12, wherein the second flexiblemember is configured to engage an upper portion of an associatedextending member.
 16. The decking member of claim 15, wherein the secondflexible member has at least one flexible prong extending generallydownward from the first portion.
 17. The decking member of claim 15,wherein the second flexible member has two-prongs extending generallydown ward from the first portion.
 18. The decking member of claim 12,wherein first flexible member is a resilient tab.
 19. The decking memberof claim 12, wherein the first portion provides an opening for receivinga fastening member therein to secure the decking board to an adjacentsurface.